Ace 41 Nelson

Exhaust Energy
Recovery
2009 Annual Merit Review
Chris Nelson
Research & Technology
May 21st, 2009
ace_41_nelson
This presentation does not contain any proprietary, confidential or otherwise restricted information.
Exhaust Energy Recovery

Overview
Timeline -
Barriers Addressed -
Project Start 5/1/05

Project End 3/31/10
Percent Complete ~80%
Engine Efficiency Improvement

Cost Effectiveness of Exhaustheat-utilization systems
System integration/calibration for
optimum peformance
Budget -
Partners -
Total Project Funding
Cummins Turbo Technologies

Cummins Power Generation
Cummins Generating
Technologies
- DoE Share $3.2M

- Cummins Share $3.2M
(as of 3/1/09)
Funding Received in FY08

$1.3M
Funding Received in FY09

$0
This presentation does not contain any confidential or proprietary information.
Innovation You Can Depend On
Agenda
Program Goals
Exhaust Energy Recovery System Architecture
Program Accomplishments
First Generation Hardware Results
Engine Architecture Changes

SCR Aftertreatment Effect on Performance
System Development
Path to target
2009 Plans and Milestones

Component development and next generation hardware
Review and Summary

Program Goals
Exhaust Energy Recovery seeks to achieve:

10% Fuel Efficiency Improvement
Reduce or eliminate the need for increased heat
rejection capacity for future heavy duty engines
in Class 8 Tractors
A 10% increase in fuel efficiency would:
Save a linehaul, Class 8 truck over 1800 gallons of fuel per year
Reduce exhaust emissions due to less fuel use
Reducing the need for increased heat rejection:
Helps maintain the aerodynamic advantages of todays trucks
Exhaust Energy Recovery Concept

Ram Airflow
------------------------------------------
CAC
Converts otherwise wasted

thermal energy from the EGR
and main exhaust gas
streams
Engine
Radiator
Mechanical Fan
EGR
Valve
Intake Manifold
Exh.Manifold
FMG
Boiler
Recupe
Air In
ISX Engine
Works best for high-EGR flow

engine recipes for low-NOx
combustion
Condenser
WHR
Condenser Cooler
Superheater
Turbine
Comp
Turb
Generator
Organic Rankine Cycle
Power
Conditioning
Power Out
Exh. Boiler
Aftertreatment
Exhaust
Recipe for 10% Efficiency Improvement

Ram Airflow
WHR
Condenser Cooler
CAC
+ 2% from Exhaust
Mechanical Fan
EGR
Valve
Intake Manifold
Model-based predictions
across Heavy Duty drive cycle
Exh.Manifold
ISX Engine
Improvement
FMG
The benefit of electric

accessories is included by the
presence of high-voltage
electricity on-engine.
Boiler
Recupe
Air In
10%
Condenser
+ 2% from Electric Acc.
Engine
Radiator
Superheater
Turbine
Comp
Turb
Generator
6% from EGR energy
Power
Conditioning
Power Out
Exh. Boiler
Aftertreatment
Exhaust
Original System Architecture

Plans and Assumptions
Low engine-out NOx combustion recipe
Engine architecture used for first-generation EER system design
targeted 0.2 gm BSNOX engine-out emissions
EGR Charge Mass flow provided a high level of recoverable EGR
energy
Additional energy was recovered from the engines main exhaust
gas stream to keep the system at its full potential
EER System performance was limited to the heat rejection capacity
of a MY2007 Class 8 tractor
WHR
First Generation Hardware Design
Superheater
Preheater/Boiler
Turbine-Generator
Recuperator
feedpump
sight-glass
filter/dryer
8
WHR
First Generation Hardware Design
rear crossover
tube
Condenser
FlywheelMotorGenerator
boost pump
ISX with WHR System in Test Cell
10
1st Generation Hardware

Fuel Efficiency Improvement Results
Class 8 Tractor modeled on Heavy Duty, 500 mile route
B100
21.3 hp
A100
20.2 hp
16 hp
C100
20.2 hp
19.2hp
14.9 hp
B75
19.6 hp
18.4 hp
Engine Operating Point
B63
18.2 hp
Predicted WHR Power
16.8 hp
B50
Observed Gen1 Power
17.2 hp
15.7 hp
EGR-Only WHR Net benefit on HDCC cycle = 6% Predicted

5.4% Observed from EGR Only with 1st Generation Hardware
11
Cummins Waste Heat Recovery

Ram Airflow
WHR
Condenser Cooler
CAC
------------------------------------------
EGR
Valve
FMG
Boiler
Recupe
Intake Manifold
Air In
Exh.Manifold
Taking in additional heat

energy from the main exhaust
stream maximizes the power
supplied by the ORC
Mechanical Fan
ISX Engine
At off-peak operation, heat

rejection capacity exists in
the Recuperator and
Condenser and Rad. Pack
Engine
Radiator
Superheater
Turbine
Comp
Turb
Generator
Exhaust Energy
Recovery
Power
Conditioning
Power Out
Exh. Boiler
Aftertreatment
12
Exhaust
1st Generation Hardware Test Results
7.4% BTE Benefit
13
Recipe for 10% Efficiency Improvement

Ram Airflow
WHR
Condenser Cooler
CAC
+ 2% from Exhaust
Mechanical Fan
EGR
Valve
Electric accessories are not

being developed under this
program
Intake Manifold
Exh.Manifold
Goals were nearly achieved

with 1st Gen hardware.
Component development
would reach the 10% goal
ISX Engine
Improvement
FMG
Boiler
Recupe
Air In
9.4%
Condenser
+ 2% from Electric Acc.
Engine
Radiator
Superheater
Turbine
Comp
Turb
Generator
5.4% from EGR energy
Power
Conditioning
Power Out
Exh. Boiler
Aftertreatment
14
Exhaust
Affect of SCR Aftertreatment

Cummins announced during August of 2008 that it would use
SCR-based aftertreatment on its 2010 heavy-duty engines
This significantly reduced the amount of EGR flow required to
meet engine-out NOx emissions and improved base engine
fuel economy. However, it reduced the potential benefit of
Exhaust Energy Recovery
Our recipe to maximize the recovery of EGR and Exhaust Gas
heat within the limit of the vehicles cooling module ability
still offers significant fuel economy savings
15
1st Generation Hardware Test Results from ISX07
6.2% BTE Benefit
16
Affect of SCR Aftertreatment

Cummins has not established its 2010 and beyond engine
recipes but significant waste heat will still remain for
recovery in the EGR and Exhaust gas streams
The potential benefit from ORC-based Exhaust Energy
Recovery remains very significant and merits further
development
We are therefore identifying our path to the 10% target -
17
System Development Path to Target

WHR
Coolant Heat
Recovery
Charge Air Heat

Recovery
Exhaust Heat
Recovery
EGR Heat
Recovery
18
Vehicle/
Condenser
Capacity
Component
Efficiencies
Working
Fluid

WHR
Coolant Heat
Recovery
Charge Air Heat

Recovery
Exhaust Heat
Recovery
EGR Heat
Recovery
Vehicle/
Condenser
Capacity
Component
Efficiencies
From bulk coolant at 200F

Potential for + ~1.5% improvement
Utilize existing engine design/hardware, AEG, water pump,
Recovery from AEG to working fluid heat exchanger
Eliminate radiator, system cooling with WHR condenser only
19
Working
Fluid

WHR
Coolant Heat
Recovery
+1.5%
Charge Air Heat

Recovery
Exhaust Heat
Recovery
EGR Heat
Recovery
Vehicle/
Condenser
Capacity
Component
Efficiencies
Charge Air Heat Recovery would add +~1.2%

Recovery from Charge Air Pre-Cooler
Requires Air-Air finish cooler to meet IMT requirements
20
Working
Fluid

WHR
Coolant Heat
Recovery
+1.5% (+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
EGR Heat
Recovery
Vehicle/
Condenser
Capacity
Component
Efficiencies
Working
Fluid
Exhaust recovery performed to maximize use of heat rejection capacity

Amount of benefit depends on EGR recipe and cooling system capacity
~3.5% BTE benefit shown at 07 EGR recipe
21

WHR
Coolant Heat
Recovery
+1.5%(+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
+3.5%
EGR Heat
Recovery
Vehicle/
Condenser
Capacity
Component
Efficiencies
2.5% BTE benefit shown at 07 EGR recipe

Benefit is dependent on EGR recipe
22
Working
Fluid

WHR
Coolant Heat
Recovery
+1.5%(+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
+3.5%
EGR Heat
Recovery
+2.5%
Vehicle/
Condenser
Capacity
Component
Efficiencies
Doubling 07-based condenser size adds ~2% benefit

Assume 1% benefit is realistically achievable
Dependent on OEM Capability
23
Working
Fluid

WHR
Coolant Heat
Recovery
+1.5%(+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
+3.5%
EGR Heat
Recovery
+2.5%
Vehicle/
Condenser
Capacity
+1%
Component
Efficiencies
Turbine Efficiency at ~75% in 1st Gen

Turbine efficiency could be higher
1st Gen Power Transfer Efficiency @90% could be greater
Pump Efficiencies
1st Gen Pump Efficiencies were ~30%
Flow Losses
Valve losses
Flow losses in heat exchangers
Piping/Plumbing Flow Losses
24
Working
Fluid

WHR
Coolant Heat
Recovery
+1.5%(+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
+3.5%
EGR Heat
Recovery
+2.5%
Vehicle/
Condenser
Capacity
+1%
Component
Efficiencies
+1%
Performance is limited by fluids peak temperature

Gen1 System ran fluid temperature near 425F
Fluid breakdown is higher closer to 550F
Controls Refinement would allow operating much closer to breakdown limit
Operating at significantly higher fluid temp may achieve 1% benefit
25
Working
Fluid

WHR
~11.7%
BTE Benefit
Coolant Heat
Recovery
+1.5%(+)
Charge Air Heat

Recovery
+1.2%
Exhaust Heat
Recovery
+3.5%
EGR Heat
Recovery
+2.5%
Vehicle/
Condenser
Capacity
+1%
Component
Efficiencies
+1%
Working
Fluid
+1%
The addition of Coolant and Charge Air heat is done within the existing cooling
system capacity
Refinements to system components and controls offer an avenue toward significantly
greater benefit from ORC Energy Recovery
ORC-based energy recovery offers the greatest engine efficiency improvement
potential
26
2009 Plan and Milestones

2nd Generation Component Development
Turbine and Power Transfer
Mechanical gear train coupling of Turbine to Engine
Should decrease losses over electrically-based system
Should improve system robustness and overall cost
Slower speed turbine

Should improve turbine efficiency
Heat Exchanger Design and Development

2nd Generation EGR Boiler/Superheater more production-like design
Exhaust Boiler, Recuperator, CAC Pre-Cooler, and Coolant Heat
Exchangers
Addition of CAC Pre-Cooler and Coolant heat should improve system
performance
Condenser/Subcooler/Receiver Integration
Pumps and Plumbing Development

Positive Displacement Pumps (1st Gen were centrifugal)
Improved pump efficiency should decrease losses/improve system
performance
27
Milestones for 2009

2nd Generation System Development Mechanical Gear Train Design
Underway
Condenser/Subcooler/Reservoir Testing
May 09
Pump Assessment and Testing
August 09
Gear Train Component Testing (Start)
September 09
2nd Generation Turbine Testing
Q4 09
2nd Generation Engine Builds
Q1 2010
28
Review and Summary

The Exhaust Energy Recovery program at Cummins
has made considerable progress
Successfully demonstrated ORC-based energy recovery
from EGR and Exhaust gas
Delivered results against our model-based predictions for
system performance
Identified areas for system improvements
Identified avenues for development towards the 10% Goal
29
Cummins Waste Heat Recovery

Cummins Inc. Appreciates the Partnership Support of
the U.S. Department of Energy in this highly
innovative and unique program
Thank You!
30

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Exhaust Energy

Exhaust Energy Recovery

Project Start 5/1/05

Engine Efficiency Improvement

Total Project Funding

Cummins Turbo Technologies

- DoE Share $3.2M

Funding Received in FY08

Funding Received in FY09

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

Engine Architecture Changes

2009 Plans and Milestones

Review and Summary

Innovation You Can Depend On

Exhaust Energy Recovery seeks to achieve:

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

Exhaust Energy Recovery Concept

Converts otherwise wasted

Works best for high-EGR flow

Organic Rankine Cycle

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

Recipe for 10% Efficiency Improvement

The benefit of electric

+ 2% from Electric Acc.

6% from EGR energy

Innovation You Can Depend On

Original System Architecture

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

Innovation You Can Depend On

ISX with WHR System in Test Cell

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

1st Generation Hardware

Engine Operating Point

Predicted WHR Power

Observed Gen1 Power

EGR-Only WHR Net benefit on HDCC cycle = 6% Predicted

Innovation You Can Depend On

Cummins Waste Heat Recovery

Taking in additional heat

At off-peak operation, heat

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

1st Generation Hardware Test Results

7.4% BTE Benefit

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

Recipe for 10% Efficiency Improvement

Electric accessories are not

Goals were nearly achieved

+ 2% from Electric Acc.

5.4% from EGR energy

Innovation You Can Depend On

Engine Architecture Changes

Affect of SCR Aftertreatment

This presentation does not contain any confidential or proprietary information.

Innovation You Can Depend On

1st Generation Hardware Test Results from ISX07